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Separate outer side wall - AR63.10-P-0805-01TA

Fig 1: Identifying Cutting Templates (211 589 05 23 00)
G07271084Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 2: Identifying Spot Weld Milling Cutter (201 589 00 51 00)
G07271085Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
COMMERCIALLY AVAILABLE TOOLS

Number Designation
WH58.30-Z-1006-01A Vario Drill WS 91 spot weld removing tool
WH58.30-Z-1001-03A Round wire brush, braided, dia. 70 mm
WH58.30-Z-1004-20A Hot-air gun
WORKSHOP EQUIPMENT

WE58.40-Z-1001-03A Drill (electric/pneumatic)
WE58.40-Z-1004-03A Body saw (electric/pneumatic)
WE58.40-Z-1005-03A Wet/dry vacuum cleaner
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42
Fig 3: Identifying Outer Side Wall Cutting Marker Line Areas
G07271086Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Dimensions: 

  1. Mark cutting line (area B).
  2. Mark cutting line (area T).

    IMPORTANT Mark marker line with SPECIAL TOOL cutting template (area A). Then mark cutting line approx. 3 mm (a) offset toward rear with cutting template SPECIAL TOOL (area T).

    IMPORTANT Secure cutting template with safety pin for marker line (area A) SPECIAL TOOL

  3. Cut with body saw (areas B and T).

    NOTES Do not damage C-pillar and or outside of longitudinal member below to prevent reduction of stability.

    Fig 4: Identifying Outer Side Wall Spot Welding Areas (D, E, F And G)
    G07271087Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  4. Expose spot welds (areas D, E, F and G).
  5. Cut out spot welds with SPECIAL TOOL spot weld milling cutter or COMMERCIALLY AVAILABLE TOOLS Vario Drill spot weld removing tool (areas D, E, F and G).
    Fig 5: Identifying Outer Side Wall Spot Welding Areas (C, H, I, J, K, L And M)
    G07271088Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  6. Expose spot welds (areas C, H, I, J, K, L and M).
  7. Cut out spot welds with SPECIAL TOOL spot weld milling cutter or COMMERCIALLY AVAILABLE TOOLS Vario Drill spot weld removing tool (areas C, H, I, J, K, L and M).
    Fig 6: Identifying Outer Side Wall Spot Welding Areas (N, O, P, Q And R)
    G07271089Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  8. Expose spot welds (areas N, O, P, Q and R).
  9. Cut out spot welds with SPECIAL TOOL spot weld milling cutter or COMMERCIALLY AVAILABLE TOOLS Vario Drill spot weld removing tool (areas N, O, P, Q and R).
  10. Heat side wall in cross-hatched areas with hot air gun. COMMERCIALLY AVAILABLE TOOLS

    IMPORTANT Cross-hatched areas are foam-protected and glued.

  11. Remove side wall
    Fig 7: Identifying Side Wall Cross-Hatched Areas
    G07271090Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
    Fig 8: Identifying Side Wall Grind Mating Surfaces Cross-Hatched Areas
    G07271091Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  12. Grind mating surfaces in cross-hatched areas down to bare metal with IMPORTANT round wire brush.

    IMPORTANT Grind spot weld flanges down to bare metal on both sides.

  13. Remove grinding and drill shavings with wet/dry vacuum cleaner.
  14. Coat insides of spot weld flanges with zinc dust paint.
    Fig 9: Identifying Side Wall Grind Mating Surfaces Cross-Hatched Areas
    G07271092Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  15. Grind mating surfaces in cross-hatched areas down to bare metal with COMMERCIALLY AVAILABLE TOOLS round wire brush.

    IMPORTANT Grind spot weld flanges down to bare metal on both sides.

  16. Remove grinding and drill shavings with wet/dry vacuum cleaner.
  17. Coat insides of spot weld flanges with zinc dust paint.
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